Body armor

ABSTRACT

Body armor formed from a piece of fabric ( 1 ) comprising a plurality of layers of strong fabric with layers of film adhesive interposed between at least two adjacent ones of said layers of fabric. The layers of fabric are compressed together in at least one region. A rigid, e.g. ceramic, plate ( 4 ) is bonded to the fabric in said at least one region.

BACKGROUND TO THE INVENTION

This invention relates to body armor.

Known soft body armor is made from strong fabric, such as aramid, and is capable of stopping low-velocity fragments and soft-headed bullets. In order to upgrade this soft body armor so as to stop high-velocity fragments and armor-piercing rounds, a hard-faced plate is inserted into a pocket in the soft body armor. The plate is usually made from a ceramic material backed by a strong fabric such as aramid. The soft body armor can be in the form of a garment and can include more than one pocket, each pocket being arranged to contain a rigid plate.

This known combination of rigid and soft armor is effective, but is relatively thick, heavy and expensive to manufacture.

SUMMARY OF THE INVENTION

With the aim of alleviating these disadvantages, the present invention provides body armor comprising a piece of soft, strong fabric, and at least one rigid armor plate bonded to a portion only of said piece of fabric.

The piece of fabric may comprise a plurality of layers, e.g. of aramid fabric. In the region in which the rigid plate is bonded thereto, said layers may be compressed together. A film of adhesive may be disposed between each two adjacent layers of fabric, at least in the region in which the rigid plate is bonded to the piece of fabric.

The at least one rigid armor plate may comprise ceramic material.

In an embodiment of the invention, the rigid armor plate is bonded to a central region of the piece of fabric, which is arranged to cover a wearer's chest and abdomen, lateral regions of the piece of fabric being arranged to cover the wearer's sides.

The invention also provides a method of forming body armor, comprising the steps of: forming a piece of fabric from a plurality of layers of string fabric with layers of film adhesive interposed between at least two adjacent ones of said layers of fabric; heating said layers and compressing them together in a direction of their thickness in at least one region thereof; and bonding a rigid plate to the fabric in said at least one region.

BRIEF DESCRIPTION OF THE DRAWING

The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 shows a unit of body armor according to an embodiment of the invention; and

FIG. 2 shows a garment incorporating two units of FIG. 1.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The drawing shows a protector comprising a flexible piece of fabric 1, having a central portion 2 (e.g. a chest/abdomen portion) and two side flaps 3. In this example, the fabric 1 is aramid fabric formed in a plurality of layers, e.g. 10 to 30 layers.

At least in the chest/abdomen portion 1 layers of film adhesive, such as urethane or other suitable adhesive, is disposed between every two adjacent layers of aramid fabric. In this region a hard amour plate 4 is bonded.

Manufacture of the protector includes a step of compressing the layers of aramid fabric together in the direction of the thickness of the armor, with the application of heat, with a tool of size and shape similar to the “footprint” of the plate 4. The fabric becomes rigid in this particular region.

Subsequently, the hard armor plate 4—in this example formed of a ceramic material—is bonded to the compressed region of the fabric 1 with an adhesive such as urethane, epoxy or other suitable adhesive. The compressed layers of fabric afford to the rigid plate the same rigid backing as is provided by the aramid, ultra-high-molecular-weight polyethylene, or glass backing of the known removable plate.

In the present invention, the rigid plate 4 is permanently bonded to the soft fabric 1. In some military situations, regulations prohibit such removal of the plate and in such circumstances the permanent bond may be advantageous.

The protector can be provided with one or more straps, zips, buttons and/or other fasteners or suspension means either for suspending it from the neck or arms or for attachment to a garment. It is intended to be worn with the rigid plate 4 on the outer side.

As shown in FIG. 2, two protectors of the type depicted in FIG. 1 can be attached together by means of shoulder straps 5. They then form a tabard-style garment that can be placed over the wearer's head and fastened at the sides with a fastener such hook-and-loop closures such as Velcro ® 6, optionally arranged on straps 7. The plates 4 provide both front and rear protection.

In a modification of the protector, additional hard armor plates are bonded to side regions of the fabric 1, such as the side flaps 3, for side protection. Ultra-high-molecular-weight polyethylene fabric could be used instead of aramid. Other modifications are feasible within the scope of the claims.

The body armor of the invention provides a similar ballistic performance to the known body armor, but has a reduced thickness and weight and is less expensive to manufacture. The fabric is also simpler as it is not necessary to form a pocket for housing the rigid plate. 

1. Body armor comprising a piece of soft, strong fabric, and at least one rigid armor plate bonded to a region of said piece of fabric.
 2. Body armor according to claim 1, wherein the fabric is aramid or ultra-high-molecular-weight polyethylene fabric.
 3. Body armor according to claim 1, wherein the piece of fabric comprises a plurality of layers.
 4. Body armor according to claim 3, wherein, in the region in which the rigid plate is bonded thereto, said layers are compressed together.
 5. Body armor according to claim 1, wherein said region of said piece of fabric is a rigid region.
 6. Body armor according to claim 3, wherein a film of adhesive is disposed between each two adjacent layers of fabric, at least in the region in which the rigid plate is bonded to the piece of fabric.
 7. Body armor according to claim 1, wherein the at least one rigid armor plate comprises ceramic material.
 8. Body armor according to claim 1, wherein the rigid armor plate is bonded to a central region of the piece of fabric, which is arranged to cover a wearer's chest and abdomen or a wearer's back, lateral regions of the piece of fabric being arranged to overlie the wearer's sides.
 9. Body armor according to claim 8, including rigid armor side plates bonded to said lateral regions.
 10. A method of forming body armor, comprising the steps of: providing a piece of fabric comprising a plurality of layers of strong fabric with layers of film adhesive interposed between at least two adjacent ones of said layers of fabric; heating said layers and compressing them together in a direction of their thickness in at least one region thereof; and bonding a rigid plate to the fabric in said at least one region.
 11. A method according to claim 10, wherein the fabric is aramid or ultra-high-molecular-weight polyethylene fabric.
 12. A method according to claim 10, wherein the rigid armor plate comprises ceramic material. 